Investigation on spinnability of profiled power spinning of aluminum alloy

Abstract

Profiled power spinning is a complex metal forming process as there are many factors interrelated. The spinnability plays an important role in predicting fracture and controlling the shape of the profiled component. In this paper, a 3D finite element (FE) model is established so as to investigate on the spinnability of the ellipsoidal power spin- ning. The variation of the equivalent stress and the equivalent plastic strain are analyzed, and the analysis of variance takes comprehensive influence on the spinnability into consider- ation. The fracture behaviors of the ellipsoidal components are analyzed with the Johnson-Cook fracture criterion. The results show that the equivalent stress and the equivalent plastic strain increase with the forming time. As for the mono-factor influence, the spinnability is improved when the feed rate of the rollers decreases or the friction coefficient increases. As for the multi-factor influence, the interaction between the feed rate and the friction coefficient has a signif- icant effect on the spinnability. Theinitial fracture ispresented in the fillet part between the blank and the mandrel where the equivalent plastic strain reaches the maximum, the stress tri- axiality is the minimum, and the Johnson-Cook damage ini- tiationcriterionapproachone.Thesimulationresultsusingthe